A. Identification of Partners
The OSP consists of grey, ductile iron, and aluminum foundries located in the State of Wisconsin.
Neenah Foundry Company
2121 Brooks Ave., P.O. Box 729
Neenah, WI 54957-0729
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Main Contact: |
Tom Shallow
(920) 725-7000
tshallow@nfco.com |
ThyssenKrupp Waupaca, Inc. (Wisconsin locations)
311 S. Tower Road, P.O. Box 249
Waupaca, WI 54981
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Main Contact: |
Kim Voss
(715) 258-6611
vossk@tka-waupaca.thyssenkrupp.com |
Brillion Iron Works, Inc.
200 Park Ave., P.O. Box 127
Brillion, WI 54110-0127
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Main Contact: |
Scott Huguet
(920) 756-6686
shuguet@brillionironworks.com |
Roloff Manufacturing Corporation
400 Gertrude St., P.O. Box 7002
Kaukauna, WI 54130-7002
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Main Contact: |
Dave Roloff
(920) 766-3501
daver@roloffmfg.com |
Manitowoc Grey Iron Foundry, Inc.
2701 Division St., P.O. Box 548
Manitowoc, WI 54221-0548
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Main Contact: |
Rob Peaslee
(920) 684-0311
manitowocgreyiron@ameritech.net |
Wisconsin Aluminum Foundry Co.
838 South 16th Street, P.O. Box 246
Manitowoc, WI 54221-0246
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Main Contact: |
Jim Behnke
(920) 682-8286
jbehnke@wafco.com |
Occupational Safety and Health Administration (OSHA)
1648 Tri-Park Way
Appleton, WI 54914
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Main Contact: |
Mel Lischefski
(920) 734-4521
lischefski.melvin@dol.gov |
OSHA Region V Ergonomist
230 S. Dearborn Street, 32nd Floor
Chicago, IL 60604
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Main Contact: |
Dana Root
(312) 886-4477
root.dana@dol.gov |
OSHA Health Response Team
OSHA Salt Lake Technical Center
8660 S. Sandy Parkway
Sandy, UT 84070
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Main Contact: |
Brett Besser
(801) 233-4911
bessser.brett@dol.gov |
Labor Unions
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GMP, Local 121B
Neenah Foundry
GMP, Local 301
Manitowoc Grey Iron Foundry
United Steelworkers of America, Local 125
Glass, Molders, Pottery, Plastics & Allied Workers Local 301
International Association of Machinist & Aero Space Workers Local 516
Wisconsin Aluminum Foundry
GMP, Local 271
Roloff Manufacturing Corporation
PACE, Local 70475
Brillion Iron Works |
Wisconsin Health Consultation Program
Wisconsin State Laboratory of Hygiene
University of Wisconsin
2601 Agriculture Drive
PO Box 7996
Madison, WI 53707-7996
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Main Contact: |
George Gruetzmacher
(609) 226-5245
gruetgr@mail.slh.wisc.edu |
Other foundries may want to experience the benefits of this Partnership. New partners must be
approved by all the members and meet the following conditions:
- Agree to abide by the terms of the partnership
- Demonstrate commitment to safety and health.
- Sign the Partnership.
Acronyms:
AD: Area Director
CAS: Compliance Assistance Specialist
DAFWII – Days Away From Work Injury and Illness
DART – Days Away Restricted and Transferred
EISA: Expedited Informal Settlement Agreement
FIRM: Field Inspection Reference Manual
GMP: Glass, Molders, Pottery, Plastics & Allied Workers
FEP: Foundry Ergonomic Partnership
MSD: Muscular Skeletal Disorder
OSP(P): OSHA Strategic Partnership (Program)
OSHA: Occupational Safety and Health Administration
PACE: Paper Allied Industrial Chemical & Energy
RA: Regional Administrator
Definitions:
DART rate: The DART rate includes cases involving days away from work, restricted work activity, and
transfers to another job. It is calculated based on (N ÷ EH) x (200,000) where N is the number of
cases involving days away and/or restricted work activity, and/or job transfer; EH is the total
number of hours worked by all employees during the calendar year; and 200,000 is the base number of
hours worked for 100 full-time equivalent employees.
DAFWII rate: The DAFWII case rate is the number of cases that involve days away from work per 100
full-time equivalent employees. Cases that involve only temporary transfers to another job or
restricted work are not included. It is calculated based on (N ÷ EH) x (200,000) where N is the
number of cases involving days away from work; EH is the total number of hours worked by all
employees during the calendar year; and 200,000 is the base number of hours worked for 100 full-time
equivalent employees. Note: The DART and DAFWII rates are differentiated by the makeup of N in the
calculation formula. For the DAFWII rate, N is equal to the total of Column H from the OSHA-300 Log
(or Columns 3 and 10 from the OSHA-200 Log).
Median: a value in an ordered set of values below and above which there is an equal number of
values.
B. Purpose and Scope
The foundry industry recognizes the importance of ergonomics and has chosen to be proactive in
reducing ergonomic injuries in their industry. This OSP is formed to establish a cooperative effort
to develop policies, practices, and processes designated to decrease the incidence and severity of
musculoskeletal disorders (MSD’s) in the foundry industry. These best practices will be shared with
our employees, and employees in related industries, as well as the public as appropriate.
C. Goals/ Strategies
The overall goal of the OSP is reduction of employee injuries and illnesses by implementing
effective safety and health management systems and elimination of serious hazards.
Goal No. 1: Develop guidelines and implement a successful ergonomic program.
Strategy: Members of the OSP will develop an Ergonomics Program to reduce ergonomic hazards. The
program will be in writing and include the following elements:
- Management leadership and responsibility, and employee involvement.
- Medical management.
- Purpose, goals and objectives.
- MSD Determination and procedure.
- Ergonomic Risk Analysis.
- Implementation of Controls
- Risk Control – types of control
- Training and Education
- Each company to develop and train an ergonomic committee.
- Recordkeeping
Goal No. 2: Reduce the incidence and severity of MSD’s at participating facilities.
Strategy: Compare injury and illnesses data to the baseline (2002) and subsequent years to evaluate
the effectiveness of the ergonomic program.
Goal No. 3: Analyze workstations and work processes for ergonomic hazards and decrease or eliminate
risk factors.
Strategy: A standard ergonomic rating tool will be used to evaluate workstations/processes. The
rating will be based upon the worker’s opinion and the magnitude of the risk factors. Risk control
measures that are technically and economically feasible will be implemented to lower the rating.
Goal No.4: Develop materials that demonstrate best practices in the foundry ergonomic arena.
Strategy: Document ergonomic control measures and best practices. Publicize information that
demonstrates how an ergonomics program adds value and increases profitability. Organize the
information gained from this partnership into a format that can be used for outreach, training, and
guidance. Share this information with other foundries and the public.
D. Performance Measures
Goal No 1: Develop guidelines and implement a successful ergonomic program.
Performance Measures:
- Verify that all partners have:
- Written ergonomic programs.
- Ergonomics committees that have been trained on the signs and symptoms of musculoskeletal
disorders and ergonomic control measures.
- Report the number of people trained in ergonomics.
- Develop a model program for release on the OSHA website.
Goal No. 2: Reduce the incidence rate and/or severity of MSD’s at participating facilities.
Performance Measures:
- Calculate the DART and DAFWII incidence rates for each establishment and compare them to the
baseline (2002) and subsequent years. Incident rates will be determined for:
- Injuries and illnesses related to MSDs.
- All injures and illnesses.
- Severity will be based upon:
- Average and median number of days away from work
- Average and median number of days of restricted work activity
- Severity will be measured for each establishment and corporately for all the establishments
combined.
Goal No. 3: Analyze workstations and work processes for ergonomic hazards and decrease or eliminate
risk factors.
Performance Measures:
- The number of workstations/processes analyzed.
- Ergonomic improvements will result in lower ratings in the ergonomic evaluation assessment.
Success in decreasing or eliminating risk factors will be measured by the following:
- Number of times a reduction was achieved in a specific risk category (reported by category).
- The average magnitude of reductions for specific risk categories.
- The average change in the overall rating for the workstation/process.
Goal No.4: Develop materials that demonstrate best practices in the foundry ergonomic arena.
Performance Measures:
- Develop a best practices handbook, video, or power point presentation showing possible solutions
to ergonomic hazards. Include failures, as well as successes, and provide information on the cost of
controls and the return on investment.
- Present the accomplishments of this partnership at seminars and conferences.
- Prepare information for publication on OSHA’s Web site
- Develop training materials
E. Annual Evaluation
Data and information needed to complete the Annual Evaluation will be provided to OSHA by the
Partnership members by September 1 of each year. The Compliance Assistance Specialist (CAS) will
draft the evaluation. The Annual Evaluation will identify the strengths and weaknesses of the OSP
strategies and progress with regard to meeting the OSP goals. The Annual Evaluation will be
completed by June 1 using the standardized OSPP Annual Partnership Evaluation Report format
F. Benefits
OSHA Non-Enforcement benefits:
Outreach, technical assistance and training are available to OSP participants. Examples include:
- Priority consideration for free onsite OSHA-funded Consultation.
- OSHA personnel may be available for a variety of onsite/offsite activities such as review of
safety and health management systems, and guidance in conducting workplace audits and evaluations.
- OSHA seminars, workshops, and other speaking events.
- Informational material such as safety and health brochures, pamphlets and electronic tools.
OSHA Enforcement Benefits:
- OSHA will provide an additional 10% reduction for good faith beyond reductions provided in the
FIRM when calculating initial penalties. Maximum good faith would be 35%.
- The Area Director under the authority delegated by the Regional Administrator (RA), has the
authority to negotiate the amount of penalty reduction as part of an informal settlement agreement.
G. OSHA Verification
Each partnering employer may choose from either of the following options:
- Offsite Verification: Reviews by OSHA of the OSP data, reports, records, without actual entry to
the partner’s worksite.
- Onsite Non-enforcement Verification: OSHA conducts reviews of the partner’s worksite in a
non-enforcement capacity to assess the implementation of the OSP agreement. This onsite review will
consist of accompanying the OSP inspection team. During such visits, if OSHA personnel identify
serious hazards that site management refuses to correct, OSHA could make a referral for an
enforcement inspection.
H. OSP Management and Operation
- The effective entry date for an OSP participant will be the date the Partnership Agreement is
signed.
- OSP participants will meet quarterly at one of the participant’s facility. Minutes of all meetings
will be taken and distributed.
- Each OSP participant will send at least one representative to every meeting. This representative
must be trained in the use of the ergonomic risk evaluation tool and be knowledgeable in ergonomic
control measures.
- The OSP will evaluate a minimum of one work station/process during each meeting and suggest
changes to decrease or eliminate risk factors.
- If the establishment is represented by a Union, a union representative must be given the
opportunity to participate.
- A member of the host ergonomic committee will participate in all onsite activity.
- Participants will collect the data and best practices needed to prepare the annual evaluation and
accomplish OSP goals.
- The Health Response Team will assist with the identification of ergonomic control measures and
help develop e-tools and other web applications.
- The Wisconsin Health Consultation Program will participate in onsite evaluations and provide
technical support.
- Confidentiality:
- The OSP partners intend to provide confidential commercial information to OSHA under this
agreement of a kind not customarily made public. OSHA will protect any confidential commercial
information submitted from public disclosure to the fullest extent permitted under the Freedom of
Information Act (5 U.S.C. 552).
- OSP participants will be given a six month deferral from programmed inspections starting from
their entry into a partnership. The deferral will begin on September 21, 2005.
- Nonserious violations corrected during an enforcement inspection will not be cited. Enforcement
inspections will be conducted as expeditiously as possible.
- Where partnership facility, who is meeting the conditions of the OSP, has received an enforcement
inspection, the Area Director (AD) will request approval from the RA to extend the normal inspection
deletion criteria for an additional year.
- General duty clause citations for ergonomic hazards, Section 5(a)(1) of the Act, will not be
issued to OSP establishments that have implemented programs to reduce ergonomic hazards
- Expedited Informal Settlement Agreements (EISA) will not be less than 40%.
I. Employee and Employer Rights and Responsibilities:
This partnership does not preclude employees and/or employers from exercising any right provided
under the OSH Act (or, for federal employees, 29 CFR 1960), nor does it abrogate any responsibility
to comply with the Act.
J. Term of OSP
This agreement will terminate on September 21, 2008, which is three years from the date of the
signing. If any signatory of this agreement wishes to terminate their participation prior to the
established termination date, written notice of the intent to withdraw must be provided to all other
signatories. If a participant is not living up to their commitment, the remaining OSP participants
can request that they be removed from the partnership.
If OSHA chooses to withdraw its participation in the partnership, the entire agreement is
terminated. Any signatory may also propose modification or amendment of the agreement.
K. Signatures/Date:
Signature of this agreement signifies a confirmation of our commitment to the partnership and all
requirements and provisions contained in the agreement.
Agreed this date, September 21, 2005.
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